STANDARD COAXIAL CONNECTORS COAXI-KIT ISO 9001 APPROVED
RADIALL COMPANY PROFILE Since 1952, RADIALL has specialized in the field of coaxial connectors and cables assemblies. RADIALL s experience and high technology focus, combined with our large worldwide production capability have made the company a major supplier of RF coaxial connectors in the world and the number one in Europe. Head Office - Rosny sous Bois RESEARCH & DEVELOPMENT The ever increasing sophistication of microwave communication systems is continually requiring components to meet a higher level of performance. RADIALL s research and development groups understand these needs and are committed to searching for product solutions that will be needed in the future. They also are providing continued improvements to our already extensive lines of high performance products. All our engineer teams are equipped with state of the art equipment and facilities, in an effort to provide the best solutions to our customers. CAD workstation MANUFACTURING Numerical control lathe RADIALL knows that the quality of the connectors components is directly related to the mechanical precision of the machining process, along with good quality procedures. In an effort to continually meet the highest quality standards, all our production plants are equipped with the latest state of the art production equipment. RADIALL s manufacturing process maintains strict control of all procedures and incorporates all tooling, machining, surface treatment and assembly operations into the manufacturing process of each production group. 2
RADIALL COMPANY PROFILE TOTAL QUALITY MANAGEMENT Radiall has implemented in 1997 a worldwide Total Quality Management system based on a continuous improvement program of all processes of the company, focused on the total customer satisfaction. Radiall Total Quality Program is managed at all levels of the company as well as around the manufacturing processes or technical and administrative processes. Moreover, Radiall Company actively prepare the transition of its quality system to the ISO 9000 - Rev 2000 standard. QUALITY SYSTEM CERTIFICATION STATUS Currently ISO 9001 certified by BVQI for all its activities, Radiall is working to achieve QS 9000 certification for all its automotive market (followed by ISO/TS 16949 certification beginning of 2002). Base station of cellular network HIGH RELIABILITY Reliability of inter-connection systems is of the utmost importance in telecommunications applications. This industry need has led RADIALL to link high performance design, manufacturing and quality control. This has given the company the capability to produce connectors that will operate in the most stringent environments. The wide range of our product offering allows us to propose the best complete solution for your exact need. ENVIRONMENT MANAGEMENT Radiall is working in environmental way in all the chain of business from conception, industrialization, process and delivery. The standard used to implement the Environmental Management System is ISO 14 001 and Radiall has just succeed in ISO 14001 certification. Microwave test device ISO 9001 ACCREDITATION This certificate is witness to RADIALL s achievement and commitment to the Total Quality Process. RADIALL has always been, since its inception, a company committed to being a Total Quality supplier. Quality is our way of life at RADIALL. 3
CONTENTS PAGE RADIALL company profile...2-3 Introduction...5 Characteristics...6 Heads...7 Tips (Cable part)...8 Panel cut out...9 Tooling... 10-12 Assembly instructions...13-16 Index of Radiall part numbers with description...17 4
INTRODUCTION Concept You can mount any tip ( cable attachment ) with any head ( interface ) either in a straight or right angle configuration. Head + tip = Straight or R/A Advantages of flexibility A lot of combinations are possible by screwing the chosen tips and heads together since any tip is intermateable with any head. During base station installation, you may need, in a field situation, to change the configuration at the last minute: With the same head interface, the Coaxi-kit connector can be mounted either in a straight or a right angle position. It can be useful when the cable assembly is too short to be connected in a straight position. Using a Coaxi-kit, the existing cable assembly can be utilized by orienting the head to a right angle position, eliminating the need for a new cable assembly with a right angle connector. One head can be used for all the different cables from a 5 mm flexible cable size to a 1/2 inch corrugated cable! The same tip can be used for all the different interfaces of the BTS equipment which are supplied with 7/16 or N depending on the power transmitted, or manufacturer options. Advantages of cost saving By managing a lower number of P/N's you're making cost savings in qualification, purchasing, and inventory. For example, Radiall's full range represents 14 P/N ( 5 heads & 9 tips ) which are equivalent to 90 connector combinations (near 7 times more! ). The other advantage is the increase of volume by P/N which gives lower cost. Compared to a standard right angle connector, Coaxi-kit connectors use a simpler design. Including the price of the head & the tip, Coaxi-kit is a low cost right angle connector. Less stock By purchasing a Coaxi-kit, you eliminate separate stocks of complete connectors with different body styles and cable attachments, limiting the risk to run out of stock. Main performance characteristics These connectors have the same performances as standard ones, except that the frequency ranges are: - for flexible cables, from DC to 2.5 GHz, - for corrugated cables, DC-11 GHz: N series and DC-7.5 GHz: 7/16 series. Coaxi-kit with EZ fit cable attachment features a typical intermodulation value of -110 dbm. The product range Heads: - 7/16 series: plug and flange jack - N series: plug, flange jack and bulkhead jack Tips (cable attachment): - Crimp or clamp type on flexible cables (RG 58, RG 142, RG 213 or RG 214) - EZ fit type on super flexible corrugated cables (1/4, 3/8 or ½ ) All tips and heads are packaged by 20 pieces. 5
CHARACTERISTICS ELECTRICAL CHARACTERISTICS Coaxi-kit N Coaxi-kit 7/16 Impedance 50 Frequency range EZ fit type DC - 11 GHz DC - 7.5 GHz crimp and clamp type DC - 2.5 GHz Typical V.S.W.R. straight connectors right angle connectors 1.5 at 11 GHz 1.10 at 3 GHz 1.15 at 3 GHz Insertion loss (db) EZ fit type 0.07 at 11 GHz** 0.05 at 7.5 GHz** RF leakage -90 db min at 3 GHz -130 db min at 1 GHz Insulation resistance 5000 M min 10000 M min Contact resistance center contact outer contact 1m 0.2 m 0,4 m 1.5 m Working voltage in VRMS at sea level 1400 2700 Dielectric withstanding voltage in VRMS at sea level (at 70000 feet) 2500 600 4000 350 Power (W) at 40 C at 2 GHz 700 1000 MECHANICAL CHARACTERISTICS Durability (matings) 500 Engagement force 6.6 Ncm max 15 N Recommended coupling nut torque 40 to 60 Ncm (manual) 3000 Ncm (with torque wrench 170 Ncm (with torque wrench R282 303 520) R282 303 020) Proof torque 170 Ncm 3000 Ncm Coupling nut retention force 450 N 1000 N Center contact retention force axial 27 N 200 N ENVIRONMENTAL CHARACTERISTICS Temperature range -55, +155 C MATERIALS Bodies Center contact Outer contact Insulator Crimp ferrule male female Brass Brass Beryllium copper Brass PTFE Brass PLATINGS Bodies Silver (strike of BBR*) Center contact Silver Outer contact Silver (strike of BBR*) Silver * BBR : Bright Bronze RADIALL ** For other models, please consult us 6
HEADS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 series part number fig captive center contact panel finish note N 7/16 R161 901 120 1 yes plug R161 912 120 2 yes P01 flange jack R161 913 120 3 yes P02 silver + BBR bulkhead jack R185 901 000 4 yes plug R185 925 000 5 yes P03 flange jack Packaging: Standard 20 pieces - Unit add W after the P/N. 7
TIPS (CABLE PART) Fig. 1 Fig. 2 Fig. 3 Fig. 4 cable group part number fig dimensions A B C assembly finish note 5/50/S+D R280 008 030 1 M01 clamp type 5/50/S R280 651 030 2 24 3,1 5,41 M04 crimp type 5/50/D R280 651 230 2 24 3,1 5,8 M04 crimp type 10 / 50 / S R280 663 030 2 21,5 7,46 11,05 M04 crimp type 10+11 / 50 / S+D R280 017 030 3 M02 silver + BBR clamp type 11 / 50 / D R280 664 030 2 21,5 7,46 11,4 M04 crimp type 1/4" superflexible corrugated R280 021 200 4 41,7 4,7 7,95 M03 EZ fit type 3/8" superflexible corrugated R280 023 200 4 42,2 7,1 11 M03 EZ fit type 1/2" superflexible corrugated R280 022 200 4 41,7 8,8 14 M03 Packaging: Standard 20 pieces - Unit add W after the P/N. EZ fit type 8
PANEL CUT OUT P01 P02 P03 9
TOOLING TORQUE WRENCH A 1.34 (34.1) 0.118 (3) 0.7 (18) 5.904 (150) 7.125 (181) DIA 0.551 (Ø14) A Fig. 1 Gage weight positioning groove for calibration of coupling torque 255 Fig. 2 9 40 18 Fig. 3 21.5 9 27 340 part number fig coupling torque (N cm) R282 303 020 1 170 Torque wrench for hex. 18 mm (N) coupling nut R282 303 520 3 3000 Torque wrench for hex. 27 mm (7/16) coupling nut R282 303 220 2 950 Torque wrench for tightening the Coaxi-kit head on the tip R282 302 010 Not shown 450 Torque wrench for tightening the tip back nut on the cable (hex. 11 mm) R282 302 032 Not shown 800 Torque wrench for tightening the tip back nut on the cable (hex. 16 mm) note 10
TOOLING KIT: STRIPPING TOOL FOR FLEXIBLE CABLES (without cassette) part number R282 078 000 R299 510 010 cable diameter 7to15mm 2.5 to 7.6 mm STRIPPING CASSETTES part number cable stripping dimensions To be used with kit R282 078 220 8 mm / 2.5 mm R282 078 000 R282 078 225 8 mm / 12.5 mm R282 078 000 R299 511 012 8 mm / 2 mm R299 510 010 STRIPPING TOOL FOR SUPERFLEXIBLE CORRUGATED CABLES part number R282 010 030 R282 010 040 R282 010 050 designation Stripping tool for 1/4" superflexible corrugated cable Stripping tool for 3/8" superflexible corrugated cable Stripping tool for 1/2" superflexible corrugated cable 11
TOOLING RADIALL CRIMP TOOLS (DIES INCLUDED) Fig. 1 Fig. 2 part number fig cable group colour of handles R282 223 000 1 5/50 S - 5/50 D Orange 6.48 (.255) 5.41 (.213) 1.73 (.068) R282 231 000 2 10/50 D - 10.3/50 S - 11/50 D Yellow 10.54 (.415) 2.54 (.1) MIL CRIMP TOOL (MIL 22520/05-01) (DIES NOT INCLUDED) P/N R282 293 000 DIES part number cable group R282 235 011 5/50 S - 5/50 D 5.41 (.213) 1.73 (.068) R282 235 116 10/50 D - 10.3/50 S - 11/50 D 10.54 (.415) 2.54 (.1) 12
ASSEMBLY INSTRUCTIONS M01 coaxi-kit tip stripping dimensions a b c torque wrench for tightening the coaxi-kit head on tip recommended coupling torque R280 008 030 3 13 8 R282 303 220 950 N.cm 1 1.1. Strip the cable, using stripping tool R299 510 010 and cassette R299 511 012. 2 2.1. Slide the clamp nut, the washer and the V groove gasket onto the cable. 2.2. Slide clamp braid sleeve over braid. 2.3. Fold back braid and trim off surplus braid. 2.4. Trim back dielectric as shown. 3 3.1. Screw sub-assembly into the tip body. (Recommended coupling torque 450 N.cm P/N R282 302 010) Coaxi-kit 4 4.1. Mount the metallic gasket onto the tip. 4.2. Screw the coaxi-kit head on the cable sub-assembly, using torque wrench R282 303 220. 5 5.1. Solder the inner conductor onto the coaxi-kit head centre contact. 6 6.1. Mount the metallic gasket onto the nut and screw the sub-assembly onto the coaxi-kit body. 13
ASSEMBLY INSTRUCTIONS M02 coaxi-kit tip stripping dimensions a b e torque wrench for tightening the coaxi-kit head on tip recommended coupling torque R280 017 030 3 13 8 R282 303 220 950 N.cm 1 1.1. Strip the cable, using stripping tool R282 078 000 and cassette R282 078 220 2 2.1. Slide the clamp nut, the washer and the V groove gasket onto the cable. 2.2. Slide clamp braid sleeve over braid. 2.3. Fold back braid and trim off surplus braid. 2.4. Trim back dielectric as shown. 3 16/2 flats Hex. 19/flats 3.1. Screw sub-assembly into the tip body. (Recommended coupling torque 800 N.cm P/N R282 302 032) Coaxi-kit 4 4.1. Mount the metallic gasket onto the tip. 4.2. Screw the coaxi-kit head on the cable sub-assembly, using torque wrench R282 303 220. 5 5.1. Solder the inner conductor onto the coaxi-kit head centre contact. 6 6.1. Mount the metallic gasket onto the nut and screw the sub-assembly onto the coaxi-kit body. 14
ASSEMBLY INSTRUCTIONS M03 coaxi-kit tip stripping tool stripping dimensions a b c torque wrench for tightening the coaxi-kit head on tip recommended coupling torque R280 021 200 R282 010 030 R280 022 200 R282 010 050 R280 023 200 R282 010 040 5.5 5 11.5 R282 303 220 950 N.cm 1 2 3 Coaxi-kit 1.1. Strip the cable. 1.2. Do not damage the outer conductor. 1.3. Deburr cable inner conductor. 2.1. Slide the heatshrink sleeve onto the cable. 2.2. Screw manually the braid clamp nut onto cable outer conductor until stop. 3.1. Screw the assembly onto the body. WARNING: Screw (lefthand thread) the braid clamp nut with body, so that copper outer conductor is being squeezed. 4 4.1. Mount the metallic gasket onto the tip. 4.2. Screw the coaxi-kit head on the cable sub-assembly, using torque wrench R282 303 220. 5 5.1. Solder the inner conductor onto the coaxi-kit head centre contact. 6 6.1. Mount the metallic gasket onto the nut and screw the sub-assembly onto the coaxi-kit body. 6.2. Shrink the heatshrink sleeve. 15
ASSEMBLY INSTRUCTIONS M04 coaxi-kit tip stripping dimensions a b c dies included crimping tool MIL standard R282 293 000 (M22520/5-01) + dies torque wrench for tightening the coaxi-kit head on tip recommended coupling torque R280 651 030 R280 651 230 R280 663 030 R280 664 030 3 20.5 23.5 R282 223 000 Hex: 5.41 R282 231 000 Hex: 10.54 R282 235 011 (M22520/5-11) R282 235 116 (Y116 Daniels) R282 303 220 950 N.cm 1 2 3 1.1. Slide ferrule onto the cable. 1.2. Strip the cable, using stripping tool R282 078 000 and cassette R282 078 225 (only for R280 663 030 and R280 664 030). 2.1. Fan the braid. 2.2. Push the sleeve under the braid. 2.3. Slide the ferrule over the braid. (In direction F). 3.1. Crimp the ferrule. Coaxi-kit 4 4.1. Mount the metallic gasket onto the crimping sleeve. 4.2. Screw the coaxi-kit head on the cable sub-assembly, using torque wrench R282 303 220. 5 5.1. Solder the inner conductor onto the coaxi-kit head centre contact. 6 6.1. Mount the metallic gasket onto the nut and screw the sub-assembly onto the coaxi-kit body. 16
INDEX OF RADIALL PART NUMBERS Part numbers Description Page R161 901 120 ----------------- N head plug ---------------------------------------------------------------------------------------------------7 R161 912 120 ----------------- N head panel flange jack ----------------------------------------------------------------------------------7 R161 913 120 ----------------- N head panel bulkhead jack ------------------------------------------------------------------------------7 R185 901 000 ----------------- 7/16 head plug------------------------------------------------------------------------------------------------7 R185 925 000 ----------------- 7/16 head panel bulkhead jack---------------------------------------------------------------------------7 R280 008 030 ----------------- Tip clamp type for 5/50 S+D cable ----------------------------------------------------------------------8 R280 017 030 ----------------- Tip clamp type for 10+11/50 S+D cable ---------------------------------------------------------------8 R280 021 200 ----------------- Tip EZ fit type for 1/4" superflexible corrugated cable ---------------------------------------------8 R280 022 200 ----------------- Tip EZ fit type for 1/2" superflexible corrugated cable ---------------------------------------------8 R280 023 200 ----------------- Tip EZ fit type for 3/8" superflexible corrugated cable ---------------------------------------------8 R280 651 030 ----------------- Tip crimp type for 5/50 S cable---------------------------------------------------------------------------8 R280 651 230 ----------------- Tip crimp type for 5/50 D cable --------------------------------------------------------------------------8 R280 663 030 ----------------- Tip crimp type for 10/50 S cable -------------------------------------------------------------------------8 R280 664 030 ----------------- Tip crimp type for 11/50 D cable-------------------------------------------------------------------------8 R282 010 030 ----------------- Stripping tool for 1/4" superflexible corrugated cable -------------------------------------------- 11 R282 010 040 ----------------- Stripping tool for 3/8" superflexible corrugated cable -------------------------------------------- 11 R282 010 050 ----------------- Stripping tool for 1/2" superflexible corrugated cable -------------------------------------------- 11 R282 078 000 ----------------- Stripping tool for 7 to 15 mm dia. flexible cables (without cassette) ------------------------- 11 R282 078 220 ----------------- Stripping cassette------------------------------------------------------------------------------------------ 11 R282 078 225 ----------------- Stripping cassette------------------------------------------------------------------------------------------ 11 R282 223 000 ----------------- Crimp tool (dies included) ------------------------------------------------------------------------------- 12 R282 231 000 ----------------- Crimp tool (dies included) ------------------------------------------------------------------------------- 12 R282 235 011 ----------------- Dies------------------------------------------------------------------------------------------------------------ 12 R282 235 116 ----------------- Dies------------------------------------------------------------------------------------------------------------ 12 R282 293 000 ----------------- MIL crimp tool (dies not included) --------------------------------------------------------------------- 12 R282 302 010 ----------------- Torque wrench for tightening the tip back nut on the cable (hex. 11 mm)------------------ 10 R282 302 032 ----------------- Torque wrench for tightening the tip back nut on the cable (hex. 16 mm)------------------ 10 R282 303 020 ----------------- Torque wrench for hex. 18 mm coupling nut (N plug)-------------------------------------------- 10 R282 303 220 ----------------- Torque wrench for tightening the coaxi-kit head on the tip ------------------------------------- 10 R282 303 520 ----------------- Torque wrench for hex. 27 mm coupling nut (7/16 plug) ---------------------------------------- 10 R299 510 010 ----------------- Stripping tool for 2.5 to 7.6 mm dia. flexible cable (without cassette)------------------------ 11 R299 511 012 ----------------- Stripping cassette for 2.5 to 7.6 mm dia. flexible cable (without cassette) ----------------- 11 17
P/N: D1 161 CE P/N: D1 185 CE P/N: D3 445 CE P/N: D1 030 DE P/N: D1 032 DE 18